Stellar Industries 7628 User manual

Brand
Stellar Industries
Model
7628
Type
User manual
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 
Stellar Industries, Inc.
190 State Street
PO Box 169
Garner, IA 50438
800-321-3741
Fax: 641-923-2811
www.stellarindustries.com
Last Revision: 09/17/12
Subject to Change without Notification.
© 2012 Stellar Industries, Inc.
®
TM
7628 Manual Revisions
Date of Revision
September 15th, 2011
Description of Revision
New Flip Sheave Design Implemented. Updated Extention
Boom Assembly Drawings.
Section Revised
Chapter 2: Installation
Chapter 3: Assembly
Drawings
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST
Or email at the following addresses:
Technical Questions, and Information [email protected]
Order Parts [email protected]
Warranty Information [email protected]
Table of Contents
Table of Contents
Chapter 1 - Specifications ......................................................................1
Capacity Chart - Decal PN 55114 .....................................................2
Chapter 2 - Installation ...........................................................................3
Installation Overview ...........................................................................4
Control Kit - PN 54968 ..........................................................................5
Control Kit (Non-Boost) - PN 56490.....................................................6
Hydraulic Kit - PN 52264.......................................................................7
Valve Bank - PN 52265.........................................................................8
Hydraulic Installation ...........................................................................9
Winch Case Drain Installation ..........................................................10
Hydraulic System................................................................................11
Stability Procedure.............................................................................12
Decal Placement - 54970 .................................................................13
Chapter 3 - Assembly Drawings ..........................................................15
Base Assembly - PN 50364.................................................................15
Mast Assembly - PN 62795 ................................................................16
Main Boom - PN 54960 ......................................................................17
Extension Boom Assembly - PN 61831 .............................................18
Extension Boom Assembly - PN 61831 (Expanded)........................19
Main Cylinder Assembly - PN 54961.................................................20
Extension Cylinder Assembly - PN 50929 .........................................21
Snatch Block Assembly - PN 56266 ..................................................22
CDT™ Radio Transmitter Assembly - PN 56647 ...............................23
Chapter 4 - Replacement Parts ...........................................................25
 7628 Owner’s Manual
Specifications
Chapter 1 - Specifications
Model 7628 Crane
SPECIFICATION SHEET
Crane Rating: 38,000 ft-lb (5.25 TM)
Standard Boom Length: 12’6” (3.81 m) from CL of Crane
Boom Extension: 1st stage: Hydraulic 90"(228.6 cm)
2nd stage: Hydraulic 90"(228.6 cm)
Maximum Horizontal Reach: 28’6” (8.69 m) from CL of Crane
Maximum Vertical Lift: 30’4” (9.24 m)
(from crane base)
Boom Elevation: -5 to +80 degrees
Stowed Height 35.50” (90.2 cm)
(crane only)
Mounting Space Required 20 x 21 inches (50.8 x 53.3 cm)
Approximate Crane Weight 1900 lbs (885 kg)
Controls Radio control standard
for all functions.
Winch Specification
Rope Diameter: 3/8"(.952 cm)
Line pull speed: 60 ft/min (18.29 m/min)
Max. single part line: 3750 lbs (1700 kg)
Max. double part line: 7500 lbs (3400 kg)
Rotation: 400 degree power
(worm gear)
Lifting Capacities 3040 lbs @ 12’6” (375 kg @ 3.81 m)
1335 lbs @ 28’6” (605 kg @ 8.69 m)
Power Supply Required PTO & Pump
(8 gpm @ 3000 psi)
(30.3 lpm @ 207 bar)
*Subject to change without notification
7628 Owner’s Manual
0'
0 m
3'
.914m
6'
1.83 m
9'
2.74 m
12'6”
3.81 m
28'6”
8.69 m
20'6”
6.25 m
12'
3.66 m
3'
.914
6'
1.83 m
9'
2.74 m
15'
4.57 m
18'
5.49 m
21'
6.40 m
24'
7.01 m
27'
8.23 m
30' 4”
9.25 m
Weight of load handling devices are
part of the load lifted and must be
deducted from the capacity.
Maximum 1 - part line capacity is
3750 lbs (1700 kg). For greater
loads, use 2 - part line.
PN 55114
Reach in Feet/Meters
Capacity in Pounds/Kilograms
15º
30º
80º
75º
60º
45º
Boost
(If Equipped)
Standard
7500 lbs
3400 kg
7500 lbs
3400 kg
5545 lbs
2515 kg
4260 lbs
1930 kg
5030 lbs
2280 kg
3435 lbs
1555 kg
4850 lbs
2200 kg
3150 lbs
1425 kg
3720 lbs
1685 kg
3040 lbs
1375 kg
3585 lbs
1625 kg
1845 lbs
835 kg
2175 lbs
985 kg
1335 lbs
605 kg
1575 lbs
715 kg
7500 lbs
3400 kg
4685 lbs
2125 kg
5330 lbs
2415 kg
6330 lbs
2870 kg
7470 lbs
3385 kg
2555 lbs
1155 kg
3015 lbs
1365 kg
1880 lbs
850 kg
2220 lbs
995 kg
1525lbs
690 kg
1800 lbs
815 kg
1375 lbs
620 kg
1620 lbs
735 kg
1920 lbs
870 kg
2265 lbs
1025 kg
2110 lbs
955 kg
2490 lbs
1130 kg
2605 lbs
1180 kg
3075 lbs
1395 kg
3500 lbs
1585 kg
4130 lbs
1870 kg
6300 lbs
2855 kg
7430 lbs
3370 kg
6540 lbs
2965 kg
Capacity Chart - Decal PN 55114
Installation
Chapter 2 - Installation
General Installation
This chapter is designed to serve as a
general guide for the installation of a Stellar
7628 Telescopic Crane on a Stellar Service
Body. Each installation is considered unique
so certain portions of this chapter may or
may not apply to your direct application. If
a question should arise during the installation
process, please contact Stellar Customer
Service at (800) 321 3741.
This crane is designed for use with a Stellar
Service Body installed on a vehicle that
meets the minimum chassis requirements of
the crane. It is the installer’s responsibility to
assure that the crane is mounted on a
platform that will support the maximum
crane rating of this crane.
Notice:
PTO and Pump installation instructions are
provided by the corresponding
manufacturers. For more information on
which PTO and Pump fit your application,
please contact your local Stellar Distributor
or Stellar Customer Service.
Installation Notice
According to Federal Law (49 cfr part 571),
each final-stage manufacturer shall
complete the vehicle in such a manner that
it conforms to the standards in effect on the
date of manufacture of the incomplete
vehicle, the date of final completion, or a
date between those two dates. This
requirement shall, however, be superseded
by any conflicting provisions of a standard
that applies by its terms to vehicles
manufactured in two or more stages.
Therefore, the installer of Stellar cranes and
bodies is considered one of the
manufacturers of the vehicle. As such a
manufacturer, the installer is responsible for
compliance with all applicable federal and
state regulations. They are required to
certify that the vehicle is in compliance with
the Federal Motor Vehicle Safety Standards
and other regulations issued under the
National Traffic and Motor Vehicle Safety
Act.
Please reference the Code of Federal
Regulations, title 49 - Transportation, Volume
5 (400-999), for further information, or visit
http://www.gpoaccess.gov/nara/index.html
for the full text of Code of Federal
Regulations.
Notice: Read this Page Before Installation of the Crane
Important: When installing welder units to the service
bodies, it is highly recommended that a surge
protector is installed on the chassis batteries to protect
the crane radio receiver, wiring and other electronic
devices from an unexpected electrical spike or surge.
Failure to do so could result in extensive damage to
the service body and crane electrical circuit.
7628 Owner’s Manual
2
1
FRONT
Motor
Hole Mounting Detail
Ø1.063
7.38
14.75
7.38
14.75
Ø6.00
4 Places
65382
ITEM NO. PART NO.
15199
QTY.
WASHER 1.00 SAE FLAT YELLOW GR8
CAP SCR 1.00X8X3.00 HHGR8 ZY
DESCRIPTION
4
4
WARNING!
The use of this crane on a
body not capable of handling
the loads imposed on it may
result in serious injury or
death.
Installation Overview
1. Determine that the mounting location for the 6628 crane is at least 18” x 20” (45.7 x 50.8 cm).
2. Use the detail below to drill 1.06” diameter holes into the mounting plate. Run tap on the threads of the
base to be sure they are clean.
3. Use a crane or lifting device capable of lifting the weight of the Stellar crane. The Stellar 6628 weighs
approximately 1900 lbs (885 kg). Note: cranes are shipped with rotation positioned at 200 degrees of 400
degree system. This will allow for easy installation of the crane and permanent connection of all hydraulic
and electrical components prior to repositioning into the crane saddle.
4. Connect straps or chain from the lifting device to the lifting rings on the Stellar 6628.
5. Use four (4) 1” x 3” #8 bolts and four (4) #8 flat washers.
6. Install a washer on each bolt.
7. Apply Loctite Thread locker #277 to the bolts.
8. Using the lifting device, lower the Stellar 6628 just above the crane compartment and start the bolts.
Have someone assist in leveling the crane. Note: the rotation motor should be to the door side of crane
compartment and the boom should be extended back over the rear bumper.
9. Secure the crane using the mounting hardware provided. Note: longer or shorter cap screws may be
required – recommended thread engagement into crane base is 1.75” – use grade 8, zinc plated cap
screws only.
10. Torque the cap screws to 680 ft-lbs.
11. Remove supporting crane.
12. Hook-up hydraulics and electrical.
Note: If questions should arise during any portion of this installation,
please contact Stellar Customer Service at (800) 321-3741.
Installation
PN 54968
Control Kit - PN 54968
7628 Owner’s Manual
PN 56490
Control Kit (Non-Boost) - PN 56490
Installation
NOTE: USE 32" OF HOSE PROTECTOR
P/N 17288 OVER THE ROTATION HOSES
NOTE: USE 12" OF HOSE PROTECTOR
P/N 17288 OVER THE 3 WINCH HOSES
PN 52264
Hydraulic Kit - PN 52264
7628 Owner’s Manual 7628 Owner’s Manual
HYDRAULIC SCHEMATIC
4
3
1
4
3
4
3
2
PN 52265
YTQNOITPIRCSEDTRAPMETI
1 25367 RELIEF VALVE 24685/24690 1
25368 SEAL KIT 25367
2 24960 VALVE FLW CTRL PRP/JP04C3150N 0-8 1
25369 SEAL KIT 24960/25381
3 25371 VALVE SOLND 3 POS 4 WAY TAND G04571 4
25373 SEAL KIT 25371/25372
4 44532 COIL 12VDC DUETSCH CAP012H 9
Valve Bank - PN 52265
Installation
Hydraulic Installation
1. After mounting, locate the pressure and return
lines. Note: Pressure line is 3/8” hose; Winch
Case Drain Line is 3/8” hose; Return line is 1/2”
hose. Hoses are terminated using swivel fittings.
2. Install hydraulic lines per diagram below. See
next page for Case Drain Installation. Note:
Stabilizer valve supplies oil to crane using the
Power Beyond feature.
3. Install hydraulic reservoir with return filter. Attach
pump pressure line to valve, return link to tank.
4. Fill system with hydraulic oil (See Stellar®
Lubrication Recommendations for fluid details).
(Blue)
Stabilizer Functions
Stabilizer Functions
Typical Stabilizer Valve
with Power Beyond Capabilities
 7628 Owner’s Manual 7628 Owner’s Manual
Winch Case Drain Installation
Installing the winch case drain
1.
The winch case drain must run directly to the reservoir to ensure no back pressure in the line.
2.
Use 3/8” hydraulic hose and fittings rated for a minimum of 300 psi.
3.
4.
Attach one end of the winch case drain to 3/8 swivel fitting located in step 3.
5. Route the winch case drain hose directly to the reservoir.
6.
Connect the second end of the winch case drain to unshared fitting on the top of the reservoir as
shown in Fig 2.
Fig.1 Fig. 2
Locate the winch case drain line at the bottom of the crane base as shown in Fig. 1 (Blue Hose).
Note: Both the main pressure and winch case drane line use a 3/8” swivel fitting. Verify the winch
case drain is attached to the hose that is connected to the winch motor.
(Blue)
Installation 
Hydraulic System
 7628 Owner’s Manual 7628 Owner’s Manual
Definition of Stability for the Stellar Telescopic Crane
Products:
A truck is stable until the load cannot be lifted off
the ground with the winch, without tipping over the
truck. Every Stellar crane installed must be tested for
stability to determine the actual load capacity of
the final truck package. The actual test data must
be recorded and supplied with the truck at the time
of in-service and should be kept with the truck at all
times. The following procedure will test the truck
package for stability and will provide a stability
capacity chart. The load limit information shown on
the stability capacity chart is formulated on 85%
tipping.
Set Up:
1. Locate the truck on a test course in position for
loading and engage travel brakes.
2. Set stabilizers so that they make contact with firm,
level footing.
3. Operate the crane under partial load to assure
operator proficiency and proper machine
function.
4. Put the radio into Stability Test Mode:
A. Push the bottom four switches up and hold until
all lights come on (approximately 5 seconds.)
B. At this point ,the crane will have enough
capacity to handle the weight for the stability
test.
C. The radio will timeout of stability mode after 30
minutes or when the E-Stop button is pushed.
Note: The radio can only be put into stability mode
five times. After that, the radio would have to be
returned to Stellar to be reprogrammed to allow
additional stability testing. All other radio functions
will work properly even if stability mode is not avail-
able.
Test Procedure
1. Rotate the crane into Zone 1 position.
2. With the crane fully retracted and the boom
horizontal, winch the test weight off the ground.
Note: Keep weight within six inches of the ground
at all times.
3. Extend the boom outward until full extension has
been reached or until the truck becomes unstable
(Again, use the winch to keep the weight within six
inches of the ground.)
4. If the boom goes full extension without becoming
unstable, the crane is termed stable for this zone
and 100% can be written in the Zone 1 data box.
5. If the truck becomes unstable prior to going full
extension, retract the boom until the truck
becomes stable and measure the horizontal
reach in this position (center of rotation to boom
tip). This is the stable horizontal reach for this zone.
Stable horizontal reach divided by Maximum
horizontal reach multiplied by 100 equals the
percentage of rated capacity for this zone. Use
the following formula to determine the
percentage of rated capacity:
6. Record this number in the data box for Zone 1.
This is the revised capacity due to stability for this
zone.
7. Repeat this procedure for each zone until the
worksheet is completed.
8. This is the revised capacity based on stability of
this package.
7628 Stability Data
Max Horizontal Reach: 342” (From the center of
rotation to boom tip)
Boost Stability Test Weight: 1860 lbs.
Non-Boost Stability Test Weight: 1575 lbs.
Stability Procedure
Installation 
Decal Placement - 54970
 7628 Owner’s Manual 7628 Owner’s Manual
Assembly Drawings 
.YTQNOITPIRCSEDTRAPMETI
1 47869 BEARING SWING DRIVE CAST 6620 GEARTEK 1
1EDILS 004 0283 POTS245112
3C6069 MOTOR HYD ROSS MK080613AAAB1
11-65001-800 ROTOM TEKSAG151124
5D1345 FTG CPRSN 0.12NPT/0.25 TUBE2
6D1810 TBE AIR SAEJ844 TYPE A .25 (RM)1
131.0 EPIP RELPUOC GTF6522C7
8 56589 ZERK 1/8 NPT STRAIGHT LONG THREAD 1
2HS 00.2X31-05.0 RCS PAC594359
NOTE: ITEMS 1 INCLUDE GUARD & GUARD FASTENERS
8
2
3
GASKET SHOWN AS REFERENCE
4
5
6
5
7
9
1
PN 50364
Base Assembly - PN 50364
Chapter 3 - Assembly Drawings
 7628 Owner’s Manual 7628 Owner’s Manual
PN 62795
DO NOT GREASE
THESE BUSHINGS
2
1
3
4
5
3
6
10
8
7
8
9
11
13
.YTQNOITPIRCSEDTRAPMETI
112621/12601 TSAM384341
252265VB 4 SECT W/PROP STER8GPM DEUTSCH1
3C5902 WASHER 0.63 SAE FLAT YELLOW GR818
4D1034 CAP SCR 0.63-11X3.00 HHGR8 RED PATCH14
5 63517 WINCH 3750 TH2CC230246 W/120 FT ROPE 1
6 11693 CAP SCR 0.63-11X1.75 HHGR8 4
7 27813 COLLAR 0.38X0.75X0.38 UHMW2
4CNIZ TALF SSU 13.0 REHSAW34308
9C0933 CAP SCR 0.31-18X4.50 HHGR52
2COLYN 5RGHH 81-13.0 TUN243001
11 44533 BUSHING HSG3235012S 2.00X0.754
13 52490 CAP SCR 6MMX30MM HH 8.8(GR5) 4
Mast Assembly - PN 62795
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Stellar Industries 7628 User manual

Brand
Stellar Industries
Model
7628
Type
User manual
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